Cost-Effective Maintenance

Cost-Effective Maintenance

Methodology:

• Interactive course with open discussions, team exercises, videos, case studies, and presentations.
• Participants have the opportunity to discuss their organization’s maintenance approach and develop maintenance plans with the trainer and other participants.

Course Objectives:

• Understand the definition and principles of cost-effective maintenance.
• Calculate the total maintenance cost for their production facility.
• Build a work case study to eliminate waste and develop low-cost maintenance without compromising reliability.
• Use the excellence model to improve fixed maintenance costs.
• Explain the foundations of cost-effective safety and legal compliance.
• Focus on reliability efforts in a cost-effective manner.
• Develop a methodology to reduce costs, integrate reliability, and improve safety.

Target Audience:

• Maintenance managers, supervisors, planners, schedulers, reliability engineers, project managers and engineers, operations managers, transformation managers, operations supervisors, and individuals being trained for these positions.
• Contractors involved in maintenance and shutdown activities for clients.

Program Content:

1. Understanding the total cost of maintenance.

• Definition of total maintenance cost.
• Measurement criteria.
• Best practices resources.
• Key elements of fixed costs.
• Cost of lost production.
• Cost of non-compliance.
• Adding value through maintenance.
• Developing a balanced approach to cost-effective maintenance.
• Factors influencing maintenance cost effectiveness.
• Changing spending behaviors.

2. Modern maintenance strategy.

• Evolution of maintenance.
• Understanding where money can be invested and wasted.
• Importance of planning.
• Relationship between fixed costs and maintenance performance.
• Shifting mindset.
• Moving beyond cost, reliability, or safety reduction.
• Towards cost, reliability, and safety reduction.
• Modern maintenance strategy and asset management.
• Adding value through innovative maintenance and alignment with operational teams.

3. Fundamentals of reducing fixed costs.

• Understanding major spending categories.
• Determining maintenance costs.
• Root cause identification of expenses.
• Management risks associated with averages.
• Developing a program to reduce maintenance costs.
• Establishing key performance indicators and sustainable change.

4. Areas of focus for reducing fixed costs.

• Waste reduction.
• Understanding different types of maintenance.
• Common causes of waste.
• Importance of planning.
• Risk-based maintenance principles.
• Importance of maintenance standards.
• Efficiency improvements through smart workflows.
• Identifying efficiency opportunities.
• Improving downtime management.
• Enhancing maintenance methods.
• Learning from other industries.
• Implementing a planned maintenance system.
• Supply chain cost reduction.
• Contractor strategies.
• Spare parts and materials.
• Equipment services and auctions.

5. Plant performance and reliability improvement.

• Excellence model for reliability improvement.
• Reliability roadmap.
• Ensuring effective and efficient reliability improvement.
• Understanding different types of maintenance.
• Overall equipment effectiveness and other performance measures.
• Improving asset life.
• Learning from experience.
• Role of operations.
• Utilizing different maintenance types for performance improvement.
• Achieving the same performance at lower costs.

6. Cost-effective health, safety, and environment (HSE).

• Value of improving health, safety, and environment.
• How poor performance incurs unnecessary costs when safety is achieved.
• Integrating health, safety, and environment into a broader maintenance strategy.
• Legislation management.
• Risk-based inspection principle.
• Cost reduction for compliance.

7. Importance of shutdown management.

• Assets of the excellence model and why it was developed.
• Graphic model – critical elements for success.
• Planned model – exploring sub-elements.
• Detailed model – a blueprint for success.
• Importance of strategy and front-end loading principle.
• Leaders transitioning to organized work processes.
• Safety operations and quality control.
• Defining proper shutdown.
• Planning and logistics services.
• Execution and review.

8. Economic science of shutdown from prediction to closure.